High-speed multi-purpose mix load robotic end-of-arm tooling and method of using same

ABSTRACT

One or more specific embodiments disclosed herein may include a method of moving materials using an end-of-arm tool comprising aligning the end-of-arm tool over a payload, wherein the end-of-arm tool comprises an undercarriage in a retracted position, a plurality of clamp plates in an extended position, and one or more vacuum cups; lowering the end-of-arm tool towards the payload; engaging the payload with the one or more vacuum cups; engaging the payload with the plurality of clamp plates; and raising the payload into the interior of the end-of-arm tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/882,304 filed Aug. 2, 2019, as well as U.S. application Ser. No.16/945,373 filed Jul. 31, 2020, the entire disclosures of which areincorporated herein by reference.

BACKGROUND 1. Field of Inventions

The field of this application and any resulting patent is amulti-purpose, end-of-arm tool and method of using same.

2. Description of Related Art

Various devices and tools have been proposed and utilized for movingpayloads from one location to another, including some of the devices andtools in the references appearing on the face of this patent. However,those devices and tools lack all the steps or features of the devicesand tools covered by any patent claims below. As will be apparent to aperson of ordinary skill in the art, any devices and tools covered byclaims of the issued patent solve many of the problems that prior artdevices and tools have failed to solve. Also, the devices and toolscovered by at least some of the claims of this patent have benefits thatcould be surprising and unexpected to a person of ordinary skill in theart based on the prior art existing at the time of invention.

SUMMARY

One or more specific embodiments disclosed herein may include anend-of-arm tool for moving payloads from one location to another,comprising a mast system comprising a mast, a plurality of mast gussets,and a mast plate; a frame; a clamp system comprising a plurality ofclamp plates and a plurality of ball screws; and a vacuum systemcomprising a vacuum plate and one or more vacuum cups.

One or more specific embodiments disclosed herein may include a methodof moving materials using an end-of-arm tool comprising aligning theend-of-arm tool over a payload, wherein the end-of-arm tool comprises anundercarriage in a retracted position, a plurality of clamp plates in anextended position, and one or more vacuum cups; lowering the end-of-armtool towards the payload; engaging the payload with the one or morevacuum cups; engaging the payload with the plurality of clamp plates;and raising the payload into the interior of the end-of-arm tool.

One or more specific embodiments disclosed herein may include a methodof moving materials using a pallet-carry end-of-arm tool comprisingpositioning a pallet stack over a lift table on a conveyor; aligning theend-of-arm tool over the pallet stack, wherein the end-of-arm toolcomprises a plurality of claim plates in an extended position; loweringthe end-of-arm tool towards the pallet stack; activating the lift table,wherein the lift table raises the pallet stack, and further wherein thelifting table provides an overhang below the pallet stack; lowering theend-of-arm tool around the pallet stack, wherein the plurality of clampplates is positioned underneath the pallet stack; moving the pluralityof clamp plates into a retracted position; and raising the pallet stackfrom the conveyor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a multi-purposeend-of-arm tool looking down.

FIG. 2 is a side view of an embodiment of a multi-purpose end-of-armtool.

FIG. 3 is a perspective view of an embodiment of a multi-purposeend-of-arm tool looking up.

FIG. 4 is a bottom view of an embodiment of a multi-purpose end-of-armtool.

FIG. 5 is another side view of an embodiment of a multi-purposeend-of-arm tool.

FIG. 6 is a perspective view of an embodiment of a multi-purposeend-of-arm tool without side-plates.

FIG. 7 is a side view of an embodiment of a multi-purpose end-of-armtool.

FIG. 8 is a perspective view of an embodiment of a multi-purposeend-of-arm tool looking up.

FIG. 9 is a perspective view of an embodiment of a multi-purposeend-of-arm tool looking up.

FIG. 10A is a perspective view of an embodiment of a multi-purposeend-of-arm tool as it approaches a payload.

FIG. 10B is a perspective view of an embodiment of a multi-purposeend-of-arm tool as it descends over a payload.

FIG. 10C is a perspective view of an embodiment of a multi-purposeend-of-arm tool as it descends over a payload.

FIG. 10D is a perspective view of an embodiment of a multi-purposeend-of-arm tool as it engages a payload.

FIG. 11 is a perspective view of an embodiment of a pallet-carryend-of-arm tool and a gantry.

FIG. 12A is a perspective view of a pallet stack moving toward a pickuplocation on a conveyor.

FIG. 12B is a perspective view of an embodiment of a pallet-carryend-of-arm tool positioned over a pallet stack.

FIG. 12C is a perspective view of an embodiment of a pallet-carryend-of-arm tool positioned over a pallet stack, which has been raised ona lift table.

FIG. 12D is a perspective view of an embodiment of a pallet-carryend-of-arm tool encapsulating a pallet stack on a conveyor.

FIG. 12E is a perspective view of an embodiment of a pallet-carryend-of-arm tool lifting a pallet stack off of a conveyor.

FIG. 13 is a bottom perspective view of an embodiment of a pallet-carryend-of-arm tool.

FIG. 14 is a side view of a pallet stack lifted by a lift table.

FIG. 15 is a side view of an embodiment of a pallet-carry end-of-armtool engaging a pallet stack on a conveyor.

FIG. 16 is a bottom perspective view of an embodiment of a pallet-carryend-of-arm tool with the undercarriage deployed.

FIG. 17 is a perspective view of an alternative embodiment of apallet-carry end-of-arm tool with clamp bars.

DETAILED DESCRIPTION 1. Introduction

A detailed description will now be provided. The purpose of thisdetailed description, which includes the drawings, is to satisfy thestatutory requirements of 35 U.S.C. § 112. For example, the detaileddescription includes a description of the inventions defined by theclaims and sufficient information that would enable a person havingordinary skill in the art to make and use the inventions. In thefigures, like elements are generally indicated by like referencenumerals regardless of the view or figure in which the elements appear.The figures are intended to assist the description and to provide avisual representation of certain aspects of the subject matter describedherein. The figures are not all necessarily drawn to scale, nor do theyshow all the structural details of the systems, nor do they limit thescope of the claims.

Each of the appended claims defines a separate invention which, forinfringement purposes, is recognized as including equivalents of thevarious elements or limitations specified in the claims. Depending onthe context, all references below to the “invention” may in some casesrefer to certain specific embodiments only. In other cases, it will berecognized that references to the “invention” will refer to the subjectmatter recited in one or more, but not necessarily all, of the claims.Each of the inventions will now be described in greater detail below,including specific embodiments, versions, and examples, but theinventions are not limited to these specific embodiments, versions, orexamples, which are included to enable a person having ordinary skill inthe art to make and use the inventions when the information in thispatent is combined with available information and technology.

2. Certain Specific Embodiments

Now, certain specific embodiments are described, which are by no meansan exclusive description of the inventions. Other specific embodiments,including those referenced in the drawings, are encompassed by thisapplication and any patent that issues therefrom.

One or more specific embodiments disclosed herein may include anend-of-arm tool for moving payloads from one location to another,comprising a mast system comprising a mast, a plurality of mast gussets,and a mast plate; a frame; a clamp system comprising a plurality ofclamp plates and a plurality of ball screws; and a vacuum systemcomprising a vacuum plate and one or more vacuum cups.

One or more specific embodiments disclosed herein may include a methodof moving materials using an end-of-arm tool comprising aligning theend-of-arm tool over a payload, wherein the end-of-arm tool comprises anundercarriage in a retracted position, a plurality of clamp plates in anextended position, and one or more vacuum cups; lowering the end-of-armtool towards the payload; engaging the payload with the one or morevacuum cups; engaging the payload with the plurality of clamp plates;and raising the payload into the interior of the end-of-arm tool.

One or more specific embodiments disclosed herein may include a methodof moving materials using a pallet-carry end-of-arm tool comprisingpositioning a pallet stack over a lift table on a conveyor; aligning theend-of-arm tool over the pallet stack, wherein the end-of-arm toolcomprises a plurality of claim plates in an extended position; loweringthe end-of-arm tool towards the pallet stack; activating the lift table,wherein the lift table raises the pallet stack, and further wherein thelifting table provides an overhang below the pallet stack; lowering theend-of-arm tool around the pallet stack, wherein the plurality of clampplates is positioned underneath the pallet stack; moving the pluralityof clamp plates into a retracted position; and raising the pallet stackfrom the conveyor.

In any one of the tools or methods disclosed herein, the plurality ofclaim plates may comprise at least one accepting plate and at least oneinsertion plate.

In any one of the tools or methods disclosed herein, the at least oneaccepting plate and the at least one insertion plate may be positionedperpendicularly to each other.

In any one of the tools or methods disclosed herein, the end-of-arm toolmay further comprise an undercarriage system.

In any one of the tools or methods disclosed herein, the undercarriagesystem may comprise a pulley system.

In any one of the tools or methods disclosed herein, the method mayfurther comprise preprogramming the end-of-arm tool prior to thealigning step.

In any one of the tools or methods disclosed herein, the method mayfurther comprise lowering the end-of-arm tool to a preprogrammed,predetermined height over the payload or pallet stack.

In any one of the tools or methods disclosed herein, the method mayfurther comprise deploying the undercarriage.

In any one of the tools or methods disclosed herein, the end-of-arm toolmay be attached to a gantry.

In any one of the tools or methods disclosed herein, the end-of-arm toolmay further comprise a vacuum plate.

In any one of the tools or methods disclosed herein, the method mayfurther comprise lowering the vacuum plate to engage the pallet stack.

In any one of the tools or methods disclosed herein, the plurality ofclamp plates may further comprise actuating the plurality of clampplates inward, wherein the plurality of clamp plates may be positionedunder the pallet stack.

In any one of the tools or methods disclosed herein, the plurality ofclamp plates may support the pallet stack.

In any one of the tools or methods disclosed herein, the method mayfurther comprise lowering the lift table to the original position of thelift table.

3. Specific Embodiments in the Figures

The drawings presented herein are for illustrative purposes only and arenot intended to limit the scope of the claims. Rather, the drawings areintended to help enable one having ordinary skill in the art to make anduse the claimed inventions.

Referring to FIGS. 1-9 , a specific embodiment, e.g., version orexample, of a multi-purpose end-of-arm tool is illustrated. Thesefigures may show features which may be found in various specificembodiments, including the embodiments shown in this specification andthose not shown.

FIG. 1 shows an embodiment of a multi-purpose end-of-arm tool (EOAT)100, with a mast system 200, a frame 300, a clamp system 400 (shown inFIG. 3 ), a vacuum system 500 (shown in FIG. 7 ), and an undercarriagesystem 600 (shown in FIG. 8 ). In embodiments, EOAT 100 may becontrolled by wireless communication. In embodiments, mast system 200may be a multi-attachable system. Further, in embodiments, mast system200 may comprise a mast 202, one or more mast gussets 204, and a mastplate 206.

In the embodiment shown in FIG. 1 , mast 202 is shown as a squarecolumn. Mast 202 is also shown to have a vertical orientation. In otherembodiments, mast 202 may comprise a rectangular or circular column, aswell as other shapes. Further, in embodiments, mast 202 may comprisesteel 1018, aluminum, or other lightweight composites. In embodiments,mast 202 may comprise dimensions of about 6 inches by about 8 inches byabout 12 feet tall. In other embodiments, mast 202 may comprisedimensions of about 12 inches by about 12 inches by about 10 feet tall.Other embodiments may comprise other dimensions. In embodiments, mast202 may be connected to a robot or other device such as, but not limitedto, gantries, articulating robot arms, or conventional palletizingmachines, which may transport EOAT 100 and its payload. In embodiments,the top of mast 202 may be open. In embodiments, mast 202 may be boltedto a z-beam on a gantry. In those embodiments, the z-beam may havedimensions of about 0.5 inches by about 6 inches by about 8 inches withmultiple lengths. In other embodiments, mast 202 may be bolted to az-beam on an articulating robot or a high/low level conventionalpalletizing automation machine. In embodiments, EOAT 100 may receivepower through the connection to the articulating robot, conventionalpalletizing automation machine, or similar devices. In embodiments, mast202 may allow for electrically connections to a power source by use ofcables—flexible power tracks with junction boxes may be employed.

Also shown in the embodiment in FIG. 1 are the one or more mast gussets204. FIG. 1 shows three mast gussets 204 with a fourth mast gusset 204not illustrated. In embodiments, mast system 200 may comprise four mastgussets 204, eight mast gussets 204, or any other number of gussets 204needed for the particular circumstances encountered. In embodiments,mast gussets 204 may have a round, square, or rectangular shape. Incertain embodiments, mast gussets 204 may be square-shaped withdimensions of about 1.25 inches by about 1.25 inches and a thickness ofabout 0.25 inches. In embodiments, mast gussets 204 may vary indimensions and thickness depending on the payload. In embodiments, mastgussets 204 may comprise aluminum or steel. Additionally, mast gussets204 may be hollow. In embodiments, the length of the mast gussets 204may be from about 20 inches to about 30 inches. As shown in theembodiment in FIG. 1 , one end of each mast gussets 204 may be attachedto one corner of mast 202. FIG. 1 also shows that in certain embodimentsthe other end of each mast gusset 204 may be attached to a frame gusset302. In embodiments, the point of attachment of each mast gusset 204 tomast 202 may be anywhere on mast 202, but in embodiments the trianglecreated by mast 202, one mast gusset 204, and one frame gusset 302 maybe as large as possible in order to improve stability. In embodiments,each mast gusset 204 may be attached to mast 202 by bolts or by welding.In embodiments, each mast gusset 204 may be attached to each framegusset 302 by bolts or by welding.

FIG. 1 also shows an embodiment with mast plate 206. In this embodiment,mast plate 206 may be attached to the bottom of mast 202. In theembodiment of FIG. 1 , mast plate 206 has a square shape, but in otherembodiments mast plate 206 may comprise a rectangular shape. In certainembodiments wherein the mast plate 206 has a rectangular shape, mastplate 206 may comprise dimensions of about 15 inches by about 20 inches,and a thickness of about ¾ in. In embodiments, mast plate 206 maycomprise 1018 steel. Further, in embodiments, mast plate 206 may bewelded to mast 202. As further discussed below, in embodiments mastplate 206 may fit within a mast plate frame 304. In embodiments, mastplate 206 may be welded to mast plate frame 304. In embodiments, mastplate 206 may be constructed to allow for a quick change of EOAT 100.For example, mast plate 206 may be constructed to allow for a change toa smaller or different EOAT 100, if the need arises.

FIG. 2 shows an embodiment of EOAT 100 and frame 300. In embodiments,frame 300 may be generally in the shape of a square or rectangular box.In embodiments, frame 300 may comprise a top frame 306, a bottom frame308, and vertical slats 310. In embodiments, the components of frame 300may be aluminum square tubing, round chromoly with an about 1-inchdiameter, or square steel tubing with dimensions of about 0.125 inch byabout 1 inch by about 1 inch. Additionally, components of frame 300 maycomprise light-weight composites, such as carbon fiber. In embodiments,EOAT 100 may be capable of carrying payloads about 30 inches tall. Thus,in embodiments, frame 300 may comprise a height greater than 30 inches.For example, in certain embodiments, frame 300 may comprise a height ofabout 36 inches. In embodiments, the maximum horizontal size of apayload may be about 44 inches by about 52 inches. In embodiments, frame300 and its associated components may be about 12 inches to about 16inches bigger than the payload. For example, a typical industrial palletload of products may comprise a maximum size of about 60 inches by about68 inches. Thus, in embodiments, frame 300 and its associated componentsmay comprise dimensions about 12 inches to about 16 inches bigger thanthese typical industrial pallet loads of products. In embodiments, theoverall frame 300 may comprise a smaller or larger size depending on theapplication requirements. There are no limits on the dimensions of frame300. In embodiments, the different parts of frame 300 may be welded orbolted to each other. In embodiments, the different parts of frame 300may be hollow.

As shown in the embodiment of FIGS. 1 and 2 , top frame 306 may be inthe shape of a square. Further, in embodiments, top frame 306 maycomprise frame gussets 302 and mast plate frame 304. In embodiments, topframe 306 may be attached to frame gussets 302 and mast plate frame 304.In embodiments, one end of each frame gusset 302 may be attached to themast plate frame 304. In embodiments, each frame gusset 302 may beattached to the mast frame plate frame 304 at an exterior corner of themast plate frame 304. In embodiments the other end of each frame gusset302 may be attached to an interior corner of the top frame 306. Inembodiments, there may be four frame gussets 302. Other embodiments maycomprise eight frame gussets 302. Further, as shown in the embodiment ofFIG. 1 , mast plate frame 304 may comprise a square shape, but othershapes such as a rectangular shape may also be employed. In embodiments,mast plate frame 304 may comprise dimensions of about 15 inches by about20 inches. Further, mast plate frame 304 may be 1-inch square tubing.

FIG. 2 also shows an embodiment of frame 300, wherein the bottom frame308 comprises the same dimensions as top frame 306, except that bottomframe 308 does not comprise frame gussets 302 or mast plate frame 304.Further, FIG. 2 shows an embodiment of frame 300 comprising fourvertical slats 310. In embodiments, frame 300 may comprise eightvertical slates 310 or any other appropriate number.

FIGS. 3-6 show an embodiment of clamp system 400 from differentpositions. In embodiments, clamp system 400 may comprise clamp plates402, ball-screw drives 418, and an actuator 406. In embodiments, clampplates 402 may comprise first side-clamp plates 408 and secondside-clamp plates 410. In embodiments, clamp system 400 may comprise twofirst side-clamp plates 408. In embodiments, the two first side-clampplates 408 may be positioned parallel to one another and may have avertical orientation. Further, as seen in the embodiment of FIG. 4 , thefirst side-clamp plates 408 may be arranged perpendicularly to secondside-clamp plates 410. In embodiments, each of the first side-clampplates 408 may have a rectangular shape. In embodiments, firstside-clamp plates 408 may comprise ⅜-inch aluminum 6061 plate oraluminum, or light-weight composites such as carbon fiber. Inembodiments, the first side-clamp plates 408 may be sized depending onthe application. The clamping of the payload is critical. Inembodiments, “soft clamping” versus “hard clamping” may be employeddepending on the products making up the payload and the layerconfiguration. In embodiments, the force of the clamping may becontrolled ultimately with an algorithm.

As shown in the embodiment in FIG. 4 , each first side-clamp plate 408may comprise a major aperture 412 on each end. In embodiments, the majoraperture 412 may square or rectangular. In embodiments, the dimensionsof the major aperture 412 may depend upon what the product is beingclamped. For example, it may depend on whether the product requires softclamping or hard clamping. In embodiments, the major aperture 412 mayaccept the corresponding minor sections 414 of the second side-clampplates 410. In embodiments, the size and range of the major aperture 412may be determined by the range of products being picked up by EOAT 100,and therefore, the range of motion needed for each set of clamp plates402. For example, in embodiments, an implementation would allow for theclamp plates 402 to open sufficiently to accept an about 44-inch byabout 52-inch layer of payload, and to close sufficiently to secure anabout 32-inch by about 40-inch layer of payload. In embodiments, theseranges could be extended to be larger or smaller.

In embodiments, the first side-clamp plates 408 may move in a horizontalplane, and this movement may be controlled through pre-written computerprograms or by on-the-spot utilization of the algorithm. In embodiments,the two first side-claim plates 408 may move away from each other to apoint of full extension, as discussed in the previous paragraph.Further, in embodiments, the two first side-clamp plates 408 may movetowards each other to a point of full compression, as discussed in theprevious paragraph.

In embodiments, each first side-clamp plate 408 may comprise a minoraperture 416. In shown in the embodiment of FIG. 4 , the minor aperture416 may comprise a round shape. In embodiments, the minor apertures 416may be designed to accept the ball-screw drive 418. In embodiments,actuator 406 (as shown in FIG. 6 ) may be employed to rotate theball-screw drive 418. In embodiments, the ends of the ball-screw drive418 may have opposing threads such that, when the ball-screw drive 418is rotated in one direction (perhaps clockwise for example), the twofirst side-clamp plates 408 move towards each other. Likewise, when theball-screw drive 418 is rotated in the opposite direction in embodiments(perhaps counter-clockwise), the two first side-clamp plates 408 moveaway from each other. In embodiments, an actuator 406 may be employedfor each end of the two first-side clamp plates 408. Further, inembodiments, each end of each first-side clamp plate 408 may comprise abearing 420 (not illustrated) and an alignment-compliant bearing mount422 (not illustrated), through which the ball-screw drive 418 passes. Itis this mechanism of “grabbing” the ball-screw drive 418 that allows forclockwise and counter-clockwise movement of the ball-screw drive 418 inembodiments.

In embodiments, clamp system 400 may comprise two second side-clampplates 410. In embodiments, the two second side-clamp plates 410 may bepositioned parallel to one another and may have a vertical orientation.In embodiments, second side-clamp plates 410 may comprise ⅜-inchaluminum 6061 plate or aluminum, or light-weight composites such ascarbon fiber. In embodiments, the second side-clamp plates 410 may besized depending on the application. Further, in embodiments, secondside-clamp plates 410 may comprise a main section 424 and two minorsections 414. In embodiments, the main section 424 may have arectangular shape. In embodiments, the minor sections 414 may each belocated on opposite ends of main section 424. Each minor section 414 mayhave a rectangular shape in embodiments. In embodiments, each minorsection 414 may fit within the corresponding major apertures 412 of thefirst side-clamp plates 408.

In embodiments, the second side-clamp plates 410 may move in ahorizontal plane, and this movement may be controlled throughpre-written computer programs or by on-the-spot utilization of thealgorithm. In embodiments, the two second side-claim plates 410 may moveaway from each other to a point of full extension, as discussed in theprevious paragraph. Further, in embodiments, the two second side-clampplates 410 may move towards each other to a point of full compression.

In embodiments, each second side-clamp plate 410 may comprise a minoraperture 416. In shown in the embodiment of FIG. 4 , the minor aperture416 may comprise a round shape. In embodiments, the minor apertures 416may be designed to accept ball-screw drive 418. In embodiments, actuator406 (as shown in FIG. 6 ) may be employed to rotate the ball-screw drive418. In embodiments, the ends of the ball-screw drive 418 may haveopposing threads such that, when the ball-screw drive 418 is rotated inone direction (perhaps clockwise for example), the two second side-clampplates 410 move towards each other. Likewise, when the ball-screw drive418 is rotated in the opposite direction in embodiments (perhapscounter-clockwise), the two second side-clamp plates 410 move away fromeach other. In embodiments, an actuator 406 may be employed for each endof the two second side-clamp plates 410. Further, in embodiments, eachend of each second side-clamp plate 410 may comprise a bearing 420 (notillustrated) and an alignment-compliant bearing mount 422 (notillustrated), through which the ball-screw drive 418 passes. It is thismechanism of “grabbing” the ball-screw drive 418 that allows forclockwise and counter-clockwise movement of the ball-screw drive 418 inembodiments.

In the embodiment shown in FIGS. 4-6 , the clamp system 400 may compriseball-screw drives 418. In embodiments, the clamp system 400 may comprisefour ball-screw drives 418. In embodiments, the ball-screw drives 418may have a round shape. In certain embodiments, the ball-screw drives418 may have a diameter of about 1 inch to about 1.5 inches. Inembodiments, the length of the ball-screw drives 418 may be about 46inches to about 54 inches. In embodiments, the ball-screw drives 418 maybe made of steel, and the ball-screw drives 418 may have threadsmachined onto them. Another name for ball-screw drives 418 may be leadscrews. In embodiments, the ball-screw drives 418 are solid. Inembodiments, the ball-screw drives 418 may also comprise a pulley 426,which may be located at roughly the mid-point of the ball-screw drive418. In embodiments, pulley 426 may be rotated by a belt 428, whereinbelt 428 may also be connected to an actuator pulley 430. Inembodiments, the actuator pulley 430 may be connected to an actuatorshaft 432 (not illustrated), and the actuator shaft 432 may be connectedto actuator 406. In embodiments, actuator 406 may rotate the actuatorshaft 432, which in turn may rotate pulley 430. In embodiments, therotation of pulley 430 may cause the rotation of the ball-screw drive418, which may lead to the rotation of either the first side-clampplates 408 or the second side-clamp plates 410, depending on which setof clamp plates 402 the ball-screw drive 418 is connected to. Further,in embodiments, actuator 406 and ball-screw drive 418 may be connectedwith brackets 434 (not illustrated) to a side-plate 436 (as shown inFIG. 1 ), which may cover an entire side of EOAT 100, as shown in FIG. 3. In embodiments, the ends of the first side-clamp plates 408 and theends of the second side-clamp plates 410 may be supported by aslide-rail 438 (not illustrated), which may also be connected to, andsupported by, the side-plate 436.

FIG. 6 shows an embodiment of actuator 406. In embodiments, actuator 406may be a servo, electric motor, hydraulic motor, or pneumatic motor. Inembodiments, each first side-clamp plate 408 and each second side-clampplate 410 may have at least one actuator 406. In embodiments, eachactuator 406 may be programmable. In embodiments, the power source forthe actuators 406 is electrical cables (not illustrated), which passthrough flexible tracks (not illustrated). In embodiments, the actuator406 may drive the clamp plates 402 that the actuator 406 is attached to.In embodiments, actuator 406 may move its related clamp plate 402 to aspecified position, and actuator 406 may be programmed to apply a setamount of force to the payload depending on the particular payload. Inembodiments, the actuators 406 may coordinate with each other. Inembodiments, the clamp plates 402 may be moved to various positions andinstructed to apply varying amounts of pressure on a payload, dependingon the structural integrity of the payload product encountered. Inembodiments, the clamp system 400 may be programmed depending on thepayload being handled, and the clamp system 400 may be softwarecontrolled, which allows for dynamically adjusting behavior.

FIG. 7 shows an embodiment of EOAT 100 comprising vacuum system 500. Inembodiments, vacuum system 500 may comprise a plate 502 and one or morevacuum cups 504.

As shown in FIG. 7 , in embodiments, a plate 502 may hang below mastplate 206. In embodiments, plate 502 may be square or rectangular inshape. In embodiments, plate 502 may comprise ½-inch aluminum 6061 plateor ⅜-inch aluminum 6061 plate. Further, in embodiments, the dimensionsof plate 502 may vary with each implementation. Generally, inembodiments, the area of the vacuum system 500 may be smaller than thesmallest payload layer to be picked. This may allow the clamp plates 402to engage the payload at the smallest dimension of the clamp plates 402while allowing the vacuum system 500 to move up and down inside the areaof the clamp plates 402 in order to assist with picking and supportingthe payload if needed. For example, in embodiments, if the clamp plates402 engage and grip a minimum layer size of about 32 inches by about 40inches, the plate 502 may be about 30 inches by about 38 inches. Inembodiments, plate 502 may be controllable and zoned for certain pick uprequirements. In embodiments, plate 502 may be capable of up and downmovement by employing cables and idler pulleys attached to a drivepulley mounted on a servo. In embodiments, plate 502 may be bolted to amechanism (not illustrated), which causes plate 502 to ascend anddescend. In embodiments, the plate 502 may comprise a top plate 506 (notillustrated) and a bottom plate 508 (not illustrated). In embodiments,the bottom plate 508 may be machined by a CNC, which may drill andthread the bottom plate 508. In embodiments, the top plate 506 may bemachined to provide pockets. In embodiments, the top plate 506 and thebottom plate 508 are bolted to each other to create a vacuum chamber 510(not illustrated). In embodiments, the pick requirements may include asingle-product case tray, a multiple-product case tray, a row pick, or acomplete layer. Further, in embodiments, a vacuum may be applied to theplate 502 by employing pressurized air and vacuum generator, vacuumpumps, or a blower. In embodiments, these devices may be connected toplate 502 by employing a vacuum manifold and a round outlet and thenconnecting a hose from the blower vacuum manifold to the plate 502. Inembodiments, the power source for a blower, for example, may be providedby electrical cables routed through the flexible cable tracks.

In embodiments, the one or more vacuum cups 504 may be arrangedhorizontally. In embodiments, the dimensions of the array of vacuum cups504 may vary to fit as many vacuum cups 504 as possible on a givenvacuum chamber 510. In embodiments, the dimensions of each individualvacuum cup 504 may be customized for each application depending on thepayload to be picked. In embodiments, vacuum cups 504 may have adiameter of between about 2.5 inches and about 4 inches. In embodiments,vacuum cups 504 may comprise rubber, silicon, or foam edge, and thematerials employed may be customized for each application. Inembodiments, the number, size, placement, and construction of the vacuumcups 504 may vary according to the product pattern and payload at issue.Generally, one reason for employing the vacuum plate 502 for assistingwith the picking up of a payload in combination with the clamp plates402 is to allow for the following sequence in certain embodiments:lowering to product and engaging vacuum system 500, lifting the productand engaging clamp system 400; engaging the undercarriage system 600,and then releasing the vacuum created by the vacuum system 500.

FIG. 8 shows an embodiment of the undercarriage system 600. Inembodiments, undercarriage system 600 may comprise an undercarriage 602,a pulley system 604, and a drive mechanism 606 (not illustrated).

In embodiments, undercarriage 602 may comprise two pieces, and the twopieces of undercarriage 602 may be flexible. In embodiments,undercarriage 602 may comprise carbon fiber, certain fiber-clothmaterials, or slats connected to each other. In embodiments, the twopieces of undercarriage 602 may move between a retracted and an extendedposition. FIG. 8 shows an embodiment of the undercarriage system 600where the undercarriage 602 is in the retracted position, and FIG. 9shows an embodiment of the undercarriage system 600 where theundercarriage 602 is in the extended position. In embodiments,undercarriage 602 may comprise slats 608 or bars. In embodiments, thenumber of slats 608 may vary depending on the size of frame 300. Inembodiments, the slats 608 may be separated by roughly 2 inches toroughly 3 inches. In embodiments, the slats 608 may have a diameter of 1inch. In embodiments, the slats 608 may be round or square, and theslats 608 may roll freely. In embodiments, the configuration of slats608 may be a series of flat bars and round bars—or actual slats (fiber)connected with round tubes arranged to create a near solid surface. Inembodiments, the slats 608 may be connected with round fiber tubes.Alternatively, in other embodiments, the slats 608 may have a large sizeand may be composed of steel or fiber material. There are many possibleconfigurations and materials for slats 608. For example, in embodiments,steel rollers may be employed. Another possibility for slats 608 is touse the IGUS® cable track concept. Further, in embodiments, the surfaceof undercarriage 602 may be flat to improve depalletizing andpalletizing the payload.

In embodiments, slats 608 may comprise steel, aluminum, carbon fiber, orsimilar stiff, durable materials. Alternatively, the undercarriage 602may be comprised of a tightly stretched sheet, which may be comprised ofload bearing material such as mylar, plastic, or nylon webbing. Inembodiments, the undercarriage 602 may be controlled by a drivemechanism, which moves the undercarriage 602 along formed channels 610(not illustrated). In embodiments, formed channels 610 may be u-shapedand may guide the rod-ends of the undercarriage 602 as it is moved froma retracted position to an extended position and back again. Further, inembodiments, a lower corner pulley 612 may comprise a sprocket 614 (notillustrated). In embodiments, sprocket 614 may be meshed into a chain towhich the rod ends of the undercarriage 602 are attached. Inembodiments, the rotating of the lower corner pulley 612 may causesprocket 614 to rotate. In embodiments, sprocket 614 may push and/orpull the chain to which the rod ends of the undercarriage 602 areattached, back and forth along the formed channels 610.

In FIGS. 8 and 9 , the embodiment of the undercarriage system 600comprises a pulley system 604. In embodiments, there may be four groupsof pulleys with each group comprising three pulleys. In embodiments,each side of frame 300 without the undercarriage 602 may have two groupsof pulleys or six total pulleys per side. In embodiments, each group ofpulleys may form a right triangle. In embodiments, there may be thelower corner pulley 612, which may have a diameter of about 4 to 5inches; an upper corner pulley 616, which may have a diameter of about 4to 5 inches; and a lower frame pulley 618, which may also have adiameter of about 4 to 5 inches. In embodiments, the lower corner pulley612, the upper corner pulley 616, and the lower frame pulley 618 mayeach be attached to frame 300. Further, in embodiments, the lower cornerpulley 612, the upper corner pulley 616, and the lower frame pulley 618may be connected by a pulley belt 620. In embodiments, the lower cornerpulley 612, the upper corner pulley 616, and the lower frame pulley 618may be controlled by the pulley belt 620, which is controlled by drivemechanism 606. Alternatively, in some embodiments, the undercarriage 602may be controlled by a drive belt or chain. Additionally, inembodiments, the undercarriage system 600 may also comprise cameras 624(not illustrated). In embodiments, cameras 624 may be located on theupper, inside part of frame 300. In embodiments, cameras 624 may belocated adjacent to or on vacuum plate 502.

The following is an example of the operation of an embodiment of theEOAT 100, but this description is not intended to limit the method ofoperation. In embodiments, EOAT 100 may be programmed prior to operationby employing an algorithm platform. Initially, undercarriage 602 may bein the retracted position, and the clamp plates 402 may be in theextended position as shown in FIG. 3 . In embodiments, the EOAT 100 mayposition and align itself over a payload 102 as shown in FIG. 10A. Inembodiments, the EOAT 100 may then descend towards the payload 102, andthe EOAT 100 may stop its descent at a predetermined height as shown inFIGS. 10B and 10C. Next, in embodiments the vacuum cups 504 may beengaged with the payload 102. In embodiments, the clamp plates 402 maythen be engaged with the payload 102 once the payload 102 has alreadybeen picked by vacuum cups 504 as shown in FIG. 10D. In embodiments,EOAT 100 may ascend and raise the payload 102 into the interior of theEOAT 100 creating an air gap below the payload 102. In embodiments, thismay be followed by deploying the undercarriage 602 underneath thepayload 102 as shown in FIG. 9 . In certain embodiments, the payload 102may already have been picked up and the EOAT 100 moving while theundercarriage 602 is being deployed. In embodiments, the EOAT 100 mayascend and travel to its destination for the payload 102. Upon reachingits destination, the process may be reversed except that undercarriage602 may not move to a retracted position until the destinationcoordinates are reached and the EOAT 100 has descended to an appropriateheight. Thus, the EOAT 100 descends to the destination coordinates andheight for the particular payload. The appropriate height may be afunction of the dimensional distance between the target layer andundercarriage 602. Undercarriage 602 may then be retracted. The clampplates 402 may be rescinded and reengaged to square the layer to achievetied layer. The vacuum plate 502 may be lowered until the payload 102touches the surface of the destination location, and the vacuum cups 504may be disengaged. In some embodiments, the vacuum system 500 may not beengaged because it may not be required for a certain payload 102. Inthose instances, the EOAT 100 may rely on the clamp system 400 withoutthe assistance of vacuum system 500. The EOAT 100 may then ascendleaving the payload 102 at its target destination. In some embodiments,the cameras 624 may photograph and store the location for locating thepayload 102 at a later time in three-dimensional space. The edges of thelayer may be located, and this allows EOAT 100 to be repositioned suchthat, if the layer is off position, the EOAT 100 may be repositionedbefore descending.

Another embodiment, referred to as a pallet-carry EOAT 104, is anextension of the EOAT 100. The pallet-carry EOAT 104 is a bigger versionof the layer grip tool, EOAT 100. In most, if not all, respects, thepallet-carry EOAT 104 is a superset of EOAT 100. FIG. 11 shows anembodiment of the pallet-carry EOAT 104 on a dual Y-beam gantry robot106.

The pallet-carry EOAT 104 may have all of the same functions, parts, andpieces as the EOAT 100. However, there may be some differences betweenthe pallet-carry EOAT 104 and the EOAT 100. For example, the body of thepallet-carry EOAT 104 may be extended vertically compared to the EOAT100, so that the pallet-carry EOAT 104 may hold an entire pallet stackof goods, including the pallet itself. Further, in the pallet-carry EOAT104, the vertical travel of the vacuum plate 502 may have an extendedrange such that the vacuum plate 502 may raise up very high inside thetool when a full pallet is being carried. The total range of verticalmotion of the vacuum plate 502 may be about 110 inches. Additionally,the internal clamps of the pallet-carry EOAT 104 may be reinforced suchthat the internal clamp plates 402 may be placed underneath a pallet andmay be employed to lift an entire load of stacked product, including thepallet itself.

The following is a step-by-step process illustrating one method ofemploying the pallet-carry EOAT 104 to carry full pallet stacks. In FIG.12A, a pallet 108 is shown approaching the pickup location 110 on aconveyor 112. The pallet 108 may be fully loaded or may have fewer thanthe full number of layers. In FIG. 12B, the pallet 108 is shown arrivingat the pickup location 110 and is positioned/guided into a repeatablelocation by the conveyor 112. The pallet-carry EOAT 104 may positionitself above the pallet 108. In FIG. 13 , the clamp plates 402 of thepallet-carry EOAT 104 are completely open and the vacuum plate 502 ispositioned high within the pallet-carry EOAT 104. This type ofconfiguration provides space for the pallet-carry EOAT 104 to descend insuch a way as to envelop the full pallet stack 109. In FIG. 12C, thepallet 108 is shown being lifted above the surface of the conveyor 112by a custom lift table 114. FIG. 14 shows details of the pallet 108 thathas been lifted off of the surface of the conveyor 112. FIG. 14 furthershows the overhang space 116, which is the amount of area that thepallet 108 is overhanging lift table 114. This amount of overhang space116 is the clearance that will be used to position the clamp plates 402under the body of the pallet 108 and lift the pallet 108 fromunderneath. In FIG. 12D, the pallet-carry EOAT 104 is shown beinglowered around the full pallet stack 109.

In the embodiment shown in FIG. 15 , the pallet-carry EOAT 104 is shownto be positioned such that the entire width of the clamp plates 402 islower than the pallet 108. This positioning, coupled with the overhangspace 116 of the pallet 108 on all four sides, creates clearance suchthat the clamp plates 402 may be actuated inward and positioned underthe pallet 108, which may create a lifting force around the entireperimeter of the pallet 108.

In the embodiment shown in FIG. 12E, the clamp plates 402 are positionedunderneath the pallet 108 and supporting the pallet 108 around theentire perimeter of pallet 108. The vacuum plate 502 may descend to aposition where the vacuum plate 502 may rest on top of the layers of theproduct stack 109, lending additional stability to the load as it iscarried. Further, the pallet-carry EOAT 104 may raise the pallet 108,including raising the pallet stack 109 from the conveyor 112. Inembodiments, the lift table 114 may descend back to the originalposition of the lift table 114.

In FIG. 16 , an alternative embodiment of deploying undercarriage 602for additional security is illustrated. In embodiments, the pallet-carryEOAT 104 may carry the pallet stack 109 to a floor location. The floorlocation may be equipped with a stand 118 (not illustrated), which issimilar in dimension and purpose to the lifter table 114 of the conveyor112. In embodiments, the weight of the pallet 108 may rest on the floorstand 118. In embodiments, the clamp plates 402 may move to an openposition and clear of the pallet 108, when the pallet 108 is resting onthe floor stand 118. In embodiments, the pallet-carry EOAT 104 may becaused to ascend upwards and clear of the pallet 108 and stack 109,leaving the entire pallet stack 109 on the floor stand 118.

Further, in an alternative embodiment of the pallet-carry EOAT 104, asshown in FIG. 17 , the clamp plates 402 are replaced with clamp bars403, which may comprise interlacing bars as shown in FIG. 17 . Inembodiments, the clamp bars 403 may function similarly to the clampplates 402, but the clamp bars 403 may have the benefit of requiringless material. As shown in FIG. 17 , in embodiments a first set ofopposing clamp bars 403 will replace the accepting plates 408, and asecond set of opposing clamp bars 403, will replace the insertion plates410. In embodiments, the first set of opposing clamp bars 403 may beperpendicular to the second set of opposing clamp bars 403 asillustrated in FIG. 17 . Additionally, each of the clamp bars 403 maycomprise 2 or more individual bars.

Generally, the above describes an improved multi-purpose end-of-arm toolfor moving payloads from location to another, wherein the system maycomprise a mast system, a frame, a clamp system, a vacuum system, and anundercarriage system.

What is claimed is:
 1. A method of moving materials using an end-of-armtool comprising: aligning the end-of-arm tool over a pallet stack,wherein the end-of-arm tool comprises an undercarriage in a retractedposition, a plurality of clamp plates in an extended position, and oneor more vacuum cups; lowering the end-of-arm tool towards the palletstack; engaging the pallet stack with the one or more vacuum cups;positioning the plurality of clamp plates underneath the pallet stack;and raising the pallet stack into the interior of the end-of-arm tool.2. The method of claim 1, wherein the method further comprisespreprogramming the end-of-arm tool prior to the aligning step.
 3. Themethod of claim 2, wherein the method further comprises lowering theend-of-arm tool to a preprogrammed, predetermined height over the palletstack.
 4. The method of claim 1, wherein the method further comprisesdeploying the undercarriage.
 5. The method of claim 1, wherein theend-of-arm tool comprises a plurality of vacuum cups.
 6. The method ofclaim 5, wherein the dimensions of each vacuum cup are customized foreach application.
 7. The method of claim 5, wherein the materialsemployed for each vacuum cup are customized for each application.
 8. Themethod of claim 5, wherein the placement of each vacuum cup iscustomized for each application.
 9. A method of moving materials usingan end-of-arm tool comprising: aligning the end-of-arm tool over apallet stack, wherein the end-of-arm tool comprises an undercarriage ina retracted position, a plurality of clamp bars in an extended position,and one or more vacuum cups; lowering the end-of-arm tool towards thepallet stack; engaging the pallet stack with the one or more vacuumcups; positioning the plurality of clamp bars underneath the palletstack; and raising the pallet stack into the interior of the end-of-armtool.